Novelty yarn



1966 c. w. ELDRIDGE ETAL 3,269,165

NOVELTY YARN Original Filed Feb. 2, 1960 5 Sheets-Sheet l 1966 c. w. ELDRIDGE ETAL 3,269,105

NOVELTY YARN Original Filed Feb. 2, 1960 5 Sheets-Sheet 2 Aug. 30, 1966 c. w. ELDRIDGE ETAL 3,269,105

NOVELTY YARN Original Filed Feb. 2. 1960 5 Sheets-Sheet 3 NOVELTY YARN 5 Sheets-Sheet 4 Original Filed Feb. 2. 1960 NOVELTY YARN 5 Sheets-Sheet 5 Aug. 36, 1966 c. w. ELDRIDGE ETAL Original Filed Feb. 2. 1960 United States Patent 3,269,1ii5 NOVELTY YARN Clare W. Eldridge and Charles W. Long, Rock Hill, S.C., assignors to Oelanese Corporation of America, New York, NEG, a corporation of Delaware Originai application Feb. 2, 1%0, Ser. No. 6,129, now Patent No. 3,194,060, dated July 13, 1965. Divided and this application Dec. 7, 1964, Ser. No. 422,880

3 Claims. (Cl. 57-140) This application is a division of application Serial No. 6,129, filed Feb. 2, 1960, now US. Patent No. 3,194,000.

This invention relates to treated synthetic filament yarn and to apparatus for and processes of producing such yarn, particularly yarn containing or made of cellulose acetate or other organic esters of cellulose.

It is an important object of the present invention to provide processes of and apparatus for treating synthetic filament yarn so as to impart thereto novel physical and/ or visual characteristics.

Another object of the present invention is the provision of novel and highly efficacious processes of and apparatus for treating synthetic filament yarn, especially cellulose acetate yarn, so as to impart thereto intermittent varying and/ or randomly distributed physical and/ or visual properties, e.g., bulkiness and color.

A closely related object of the present invention is the provision of novel programming means for controlling the treatment as a whole and for controlling the sequence as well as the spacing and duration of the successive treatment steps or stages.

In this connection it is also an object of the present invention to provide arrangements in which the programming means, which may be of any desired type, serve to actuate a prime mover or motive device which in turn actuates means for initiating and interrupting the various treatment steps or stages.

A further object of the present invention is the pro vision of programming means as aforesaid which are capable of acting as the control for an intermittent voluminizing operation, for an intermittent chemical treatment, e.g., dyeing or dyeability-changing operation, such as saponification, or for a combination intermittent voluminizing operation and saponification.

Still a further object of the present invention is the provision of yarn-treating apparatus as aforesaid which can be combined with any desired yarn-handling apparatus, such as a downtwister, an uptwister and the like, without in any way affecting the operation of the latter and so as to permit twisting of the treated yarn.

For the purposes of the present invention, that part of the yarn treatment constituted by the voluminizing operation may be carried out by means of a crimper or a bulking jet provided with a chamber into which a high pressure fluid, such as air or steam, is admitted for contact with the yarn running through the chamber. In such a jet, which per se constitutes no part of the present invention, the bulking fluid flows in a very turbulent, vortical or otherwise non-uniform manner so as to effect the desired deformation or bulking of the yarn, i.e., of the individual filaments thereof. To effect bulking with such a device the yarn must be fed thereto at a speed greater than it is withdrawn therefrom. The degree of bulking may be varied by passing the yarn through an intermittently activated tension gate, clamp or similar device which will create a drag on the yarn so as to retard the passage of the yarn to or from the jet, depending upon the location of the tension device relative to the jet, which location will determine whether bulking or no-bulking takes place when the tension device is active. Alternatively, bulking can be varied by varying either one of the ice feed speed or take-up speed relative to the other, or by varying the length of the yarn path between feed and take-up devices as by displacement of a guide over which the yarn passes.

For that part of the yarn treatment constituted by the chemical treatment of spaced sections of the yarn, a treating device is preferably disposed between the yarn source spool or supply package and the feed rolls which draw the yarn from the said source spool to the down-twisting ring. Such a treating device may, for example, comprise a rotatable transfer ring or roller the lower half of which is immersed in a bath of dye liquor or an agent for changing the chemical composition of the yarn in conjunction with means for periodically permitting or inhibiting contact between the moving yarn and the transfer roller. When the yarn is made of a saponifiable material such as a cellulose ester the treating agent may be an inorganic saponifying agent such as caustic soda, caustic potash or sodium silicate, or an organic saponifying agent such as a methy1-amine or other lower aliphatic amine. As is well known, the saponified yarn sections of cellulose acetate yarn can be dyed by direct or cotton dyes while the unsaponified yarn sections can be dyed by normal or regular acetate dyes.

When the treatment of the yarn is to include one or more chemical treatments such as dyeing or saponification and a voluminizing operation, these operations are advantageously coordinated so that the yarn is subjected to both treatments in a single continuous pass from a source to a final position without intermediate re-winding of the yarn. As will be more fully explained hereinafter, such a set-up can be prearranged so that certain specified relationships exist between the bulked and unbu-lked yarn sections on the one hand and the saponified and unsaponified yarn sections on the other hand. The arrangement may be such that only saponified sections are bulked, or that only unsaponified sections are bulked, or that parts of adjacent saponified and unsaponified sections are bulked.

More specifically, the present invention contemplates the utilization of a variety of programming means for controlling the entire treatment. Such programming means may be purely mechanical, e.g. a cam, but preferably comprises endless pattern tape made up of transparent versus opaque or perforate versusimperforate portions which can be sensed optically, electrically, or otherwise. The sensing means is most advantageously arranged to generate electrical signals, for example upon passing of a perforated or transparent portion of the tape, which can be employed to actuate the operationinitiating elements of the bulking and/or saponifying devices.

In accordance with one aspect of the present invention, a valve is used for controlling the actuation of the aforesaid operation-initiating elements of the bulking and/or saponifying devices and in particular for controlling the actuation of the prime movers, e.g. pneumatic motors, for these elements. The valve may be a quick-acting mechanical valve provided with an operating plunger slidably engaging the suitably contoured periphery of a rotating pattern cam. The cam thus constitutes the programming means for regulating the entire treatment. The arrangement is such that for the bulking operation the valve causes the yarn tensioning device to be actuated and deactuated at such spaced intervals as are determined by the contours of the cam periphery, while for the sponification the valve causes a yarn-shifter element to bring the yarn into or out of contact with the saponifying agent transfer roller.

Alternatively, the valve may be a solenoid valve with a suitably rapid response characteristic. In this case, a perforated tape is arranged to move between a pair of spaced members of a sensing device connected to a relay or other control circuit which in turn is connected to the operating coil of the valve. The sensing device or pickup unit may comprise, by way of example, either a feeler electrode and a base electrode between which the tape slides, or a photosensitive cell and a light source between which the tape moves freely. The valve is thus actuated by electric impulses generated in response to contacts between the feeler electrode and the base electrode through the spaced openings in the pattern tape, or in response to the incidence of light on the photocell through these openings. The perforated tape thus constitutes the programming means for regulating the entire tretament. When the treatment comprises both bulking and saponifying, they can be controlled by the same or separate programming me-ans.

In accordance with another aspect of the present invention, the tensioning device or the saponifying device, or both, may be actuated directly by electromagnetic means energized in response to transmission thereto of the signals generated by the sensing devices. The valves and associated prime movers can then be dispensed with. It is further contemplated by the present invention that the said signals may also be employed to control the admission of bulking fluid into the jet if a continuous flow of bulking fluid is not desired.

The foregoing and other objects, characteristics and advantages of the present invention will be more clearly understood from the following detailed description thereof when read in conjunction with the accompanying drawings, in which:

FIG. 1 is a schematic illustration of a downtwister in combination with an intermittent bulking device con structed in accordance with the present invention;

FIG. 2 is a fragmentary schematic illustration, in perspective, of an intermittent saponifying device adapted to be operationally combined with the downtwister shown in FIG. 1;

FIG. 3 is a schematic illustration of a pattern tape, constituting the programming means for the yarn treatment, With a feeler electrode type of pick-up unit or sensing device;

FIG. 4 is a similar schematic illustration of the pattern tape with a photoelectric cell type of pick-up unit or sensing device; FIG. 5 is a schematic illustration of a contoured pattern cam, constituting the programming means for the yarn treatment, as it coacts with a treatment-controlling valve; and

FIGS. 6, 7 and 8 are block diagrams representing pos sible variations in the programming arrangement and thus in the treatments which can be carried out by the apparatus according to the present invention.

Referring now first to FIG. 1, it will be seen that the downtwister D there illustrated (which is basically a conventional structure and constitutes no part of the present invention) comprises a pair of feed rolls 10 and 11 and a downtwisting ring 12. Yarn 13, which is initially wound on a supply package or spool 14, is drawn from the latter through pigtail guides 15 and 16 by the feed rolls 10 and 11 and is fed by the latter through pigtail guides 17 and 18 to the downtwisting ring 12 by means of which the yarn is wound onto a take-up spool or package 19.

In combination with the downtwister shown in FIG. 1 there is provided, in accordance with one aspect of the present invention, a bulking device B for intermittently bulking the yarn 13. This device comprises a jet 20 and a yarn tensioning or clamping device 21 both of which are disposed along the path of travel of the yarn 13 between the feed rolls 10-11 and the downtwisting ring 12. The jet 20 essentially comprises a housing in which is defined a chamber (not shown) through which the yarn 13 is adapted to pass. Communicating with the chamber is an inlet tube or conduit 22 through which a gaseous or vaporous bulking fluid under high pressure may be admitted into the chamber.

As previously stated, the actual construction of the jet 20 comprises no part of the present invention, and thus it is not deemed necessary to illustrate the jet specifically herein. Merely by way of example, the jet 20 may be an air jet as disclosed in British Patent No. 776,410, or an air or steam jet such as those disclosed in U.S. patent application Serial No. 777,673, filed April 14, 1958 in the name of C. W. Palm, now U.S. Patent No. 3,022,563, and U.S. patent application Serial No. 812,718, filed May 12, 1959, now abandoned, in the names of James O. Smith and Carl R. Delagrange, all assigned to the assignee of the present application. Whatever type of jet is employed, however, the arrangement is such that when yarn is overfed into the jet, the fluid supplied to the bulking chamber, due to'its turbulent flow out of the chamber, causes the yarn to be deformed and rendered considerably more bulky and voluminous than it Was prior to entering the jet.

The yarn tensioning or clamping device 21 essentially comprises a pair of flat-faced discs 23 and 24, of which the disc 24 may be stationarily mounted. A pair of pins 25, 26 project from disc 24 through aligned apertures in disc 23 to ensure that a yarn threaded between the discs 23, 24 and pins 25, 26 will not be displaced to a location where it can avoid being acted upon by discs 23, 24 when the latter are in substantial contact. The disc 23 is connected to a piston rod 27 slidably extending from one end of a cylinder 28 of a double-acting pneumatic motor 29. The motor 29, which is a prime mover with respect to the tensioning or clamping disc 23 and is of conventional construction adapted to operate with air under a pressure of about 10 to p.s.i., is associated with a solenoid valve 30 which controls the flow of air through the supply line or conduit 31 into the cylinder 28. The operating coil of the valve 30 is provided with electrical leads or conductors 32 and 33 by means of which valve-actuating signals generated in a manner presently to be described may be transmitted to the coil.

The operation of the yarn-treating system so far described will be understood by considering that when the discs 23 and 24 are spaced from one another, the yarn 13 is under tension throughout its length between the feed rolls 10-11 and the downtwisting ring 12. The yarn is thus drawn out of the jet 20 as fast as it is being fed thereinto, as a result of which no bulking of the yarn will take place. At this time, therefore, the yarn is being wound onto the spool 19 while simultaneously being twisted due to the action of the downtwisting ring 12. As soon as the disc 23 is moved against the disc 24, however, to clamp the yarn 13 therebetween, feeding of yarn to the spool 19 is abruptly terminated, the rotation of the spool merely introducing twist into the portion of the yarn from discs 2324 and ring 12. At the same time, of course, the feed rolls 10 and 11, continue to feed yarn 13 into the jet 20, whereby the yarn upstream of discs 23, 24 is rendered sufiiciently slack or free of tension to be deformed and bulked by the turbulently flowing high pressure fluid leaving thebulking chamber. Upon reseparation of the clamping discs 23 and 24, tension is again applied to all of the yarn and the take-up thereof on the spool 19 again commences, so that further bulking of the yarn within the jet is inhibited. As the yarn is Wound onto the spool 19, the twist imparted by the ring 12 serves to stabilize the yarn in its deformed or bulked state to ensure that it will not straighten out upon subsequent handling.

Means are provided in accordance with the present invention for programming the opening and closing of the discs 23 and 24 and thus for releasing and clamping the yarn 13, respectively. Referring particularly to FIG. 3, it will be seen that the programming means according to this aspect of the present invention omprises a pattern tape 34 in which are provided a number of perforations or slots 35 separated by imperforate portions 36 and 37. As illustrated, the slots 35 differ from one another in longitudinal dimension or size in a completely random manner, while the imperforate portions 36 and 37 also differ from one another in size in a random manner. As alternatives it is possible, of course, to provide uniformly dimensioned slots spaced randomly, randomly dimensioned slots spaced uniformly, or uniformly dimensioned slots spaced uniformly. The pattern tape 34,.only a short portion of which is shown, advantageously is endless and adapted to be moved by any suitable drive and idler roll mechanism (not shown). The arrangement is such that the tape passes between a grounded base electrode 38 and a feeler electrode or sensing member 39 which is resiliently urged in the direction of the tape and electrode 38. The electrodes 38 and 39 are connected into the power circuit of any desired control circuit, such as an electronic relay 4% two terminals 40 and 40" of which are connected to the solenoid valve 3%) via the conductors 32 and 33.

From the foregoing it will be understood that when one of the perforations of the tape 34 is disposed between the electrodes 38 and 39, these will be in electrical contact with one another and will actuate the relay of control circuit in such a manner as to generate a signal adapted to be transmitted to and energize the coil of the solenoid valve 30. The latter is thus shifted into a position for admitting fluid into the cylinder 28 so as to move the piston rod 27 outwardly and to press the disc 23 against the disc 24. As a result, the yarn then being fed into the jet will become slack and will be bulked in the aforedescribed manner. As soon as the pick-up or feeler electrode 39 contacts an imperforate section of the tape 34, the solenoid valve 30 will be reversed due to opening the circuit for the relay 40 so as to effect admission of fluid into the cylinder 28 in a manner tending to retract the piston rod 27 and separate the disc 23 from the disc 24. The take-up of the yarn is then resumed until the feeler electrode 39 again comes into electrical contact with the base electrode 38 through the next perforation 35 in the tape 34.

It is possible, according to the invention, to substitute for the electrode type pick-up unit 38-39 a photoelectric type pick-up unit or sensing device. Such a system, illustrated in FIG. 4, comprises a lamp or other light source 41 and a photoelectric cell or similar light-sensing ele ment 42 disposed on opposite sides of the path of movement of the pattern tape 34. The light source 41 and cell 42 are connected in circuit with a relay or control circuit 43. The latter, which may be the same as the relay 4!) shown in FIG. 3, has its output terminals 43 and 43" connected with the conductors 32 and 33 leading to the coil of the solenoid valve 30. As will be readily understood, light will be incident on the cell 42 whenever the tape 34 has moved to a sufficient extent to dispose one of the perforations 35 between the cell 42 and the light source 41. When the resultant electrical signal energizes the valve coil, the dis 23 will be pressed against the disc 24 to inhibit further take-up of yarn onto the spool 19 and thus to cause an overfeeding of additional yarn 13 into and through the jet 20, whereby the yarn is bulked by the action of the high pressure bulking fluid admitted into the jet through the inlet conduit 22 thereof. As soon as an imperforate portion of the tape 34, for example that shown at 37 in FIG. 4, reaches the gap between the light source 41 and the cell or sensing element 42, the solenoid valve 30 is reversed so as to effect retraction of the disc 23 from the disc 24. Yarn take-up now again commences and, due to tension in the yarn, no further "bulking will take place until another of the perforations 35 in the pattern tape 34 is located between the light source 41 and the cell 42.

One of the principal advantages of a programming arrangement of the type shown in FIGS. 3 and 4 is that the use of a pattern tape allows attainment of great flexibility in the choice of patterns of random yarn treatments. This is due to the fact that it is possible to perforate the tape for extremely long term repeats without taking up an excessively large amount of space for the tape-driving mechanism and the associated sensing device and without complex variable speed mechanisms. For example, the tape can be endless and housed in a suitable magazine or it may be spirally unwound at constant speed from one spool to another using an inexpensive drive such as is employed for motion picture projectors or tape or wire recorders. Moreover, due to the easy interchangeability and combinability of such tapes, an almost infinite variety of random treatment patterns can be attained.

In lieu of the pattern tape 34 shown in FIGS. 3 and 4 and the associated sensing means, it is possible in accordance with the present invention to employ a mechanical programming means, as shown diagrammatically in FIG. 5. Such a mechanical programming means may be constituted, for example, by a cam 44 adapted to be rotated about an axis 45 by any suitable constant or variable speed drive means (not shown). The outer periphery of the cam 44 is contoured in a predetermined manner to provide a plurality of irregularly sized and/or irregularly spaced elevations or lobes 46 and depressions 47 the function of which will become clear presently.

In view of the mechanical nature of the pattern cam 44, the solenoid valve 3th is replaced in this embodiment of the invention by a quick-acting mechanical valve 48 which is provided with an air supply line 49 and a pair of flow lines it) and 51 adapted to be connected to the cylinder 28. The valve 48 is provided with a reciprocally displaceable valve element (not shown) controlling the communication between the supply line 49 and the flow lines 50 and 51. Attached to this valve element is a plunger 52 which extends from the housing of the valve 48 and carries a roller or like contact element 53 slidably engaging the outer periphery of the pattern cam 44. The valve element in the valve 48 is preferably spring-biased in such a direction (upwardly as shown in FIG. 5) to maintain the contact element 53 in engagement with the peripheral surface of the pattern cam 44 and to normally urge the valve element into such a position that fluid is so directed into the cylinder 28 as to separate the disc 23 from the disc 24. This condition corresponds, for example, to engagement of the contact element 53 on the plunger 52 with one of the depressions 47 on the pattern cam periphery.

From the foregoing it will be understood that as soon as the cam 44 is rotated sufficiently to bring one of the lobes or elevations 46 into engagement with the contact element 53, the valve plunger 52 and therewith the valve element will be depressed and shifted to the position in which fluid admitted into the cylinder 28 causes the piston rod 27 to be advanced and the disc 23 to be pressed against the disc 24. The yarn will then be clamped against movement past the tensioning device 21, whereupon the portion of the yarn 13 in the jet 20 at that time will be bulked as previously described. As soon as the cam rotates further to bring the next depression 47 into engagement with the contact element 53, the valve 48 will be operated to cause retraction of the piston rod 27 and separation of the disc 23 from the disc 24, thereby penmitting take-up of the yarn onto the spool 19 and inhibiting further bulking until the following elevation 46 of the cam reaches the contact element 53.

The intermittent bulking arrangement according to the present invention as heretofore described is, of course, susceptible to a number of variations. For example, it is possible to employ in lieu of the pneumatic motor-actuated clamping discs 23 and 24 a pair of discs which can be drawn against one another electromagnetically. Thus, the stationary disc 24 may be associated with a relatively powerful electromagnet while the movable disc 23 is made of a highly magnetic material. In this case, neither the pneumatic 'motor 29 nor the solenoid valve 30 or mechanical valve 48 would be needed. Instead, the electric pick-up unit 38-39 or the photoelectric pick-up unit 41-42 would be connected directly or through the intermediary of suitable control circuitry to the coil of the electromagnet associated with the disc 24. The latter would then be actuated by signals generated by the pickup unit, to draw the disc 23 against the disc 24 and thus to clamp the yarn therebetwe'en, whenever one of the perforations 35 of the pattern tape 34 is located within the range of the associated pick-up unit, i.e., either between the feeler electrode 39 and the base electrode 38 or between the photosensitive cell 42 and the light source 41. In an alternate electromagnetically actuated device, the disc 23 is carried by an armature which is displaced electromagnetically. Such electromagnetic devices are especially useful since they are cheap, compact, fast acting and easy to install and maintain.

It is further possible in accordance with the present invention to provide bulking fluid for the jet 20 only intermittently and in substantial synchronism with the actuation of the clamping device 21. To this end it would merely be necessary to connect the output of the pattern sensing device to the valve (not shown) which controls the flow of air through the line 22 into the jet. Merely by way of example, if this valve is a mechanical valve of the quick-acting type, it may be actuated by a cam identical with the pattern cam 44 and mounted on the same rotatable shaft as the cam 44. If, on the other hand, the programming means employed is of the type shown in either FIG. 3 or FIG. 4, the valve which controls the line 22 advantageously is a solenoid valve like the valve 30. It will be readily appreciated, however, that if an intermittent feeding of bulking fluid into the jet 20 is employed, such feeding of the fluid need not be in exact synchronism with the actuation of the tensioning or clamping device 21. If desired, a time delay arrangement, to which reference will be had more fully hereinafter, can be provided to permit flow of fluid into the jet either before or after the tensioning device 21 is actuated.

By supplying the bulking fluid only intermittently, its consumption is held to a minimum with attendant economic a'dvantage since no fluid is wastefully supplied when the jet is incapable of bulking due to tension on the yarn. Moreover, by supplying the bulking fluid in synchronism with the actuation of the clamping device 21 closer control of the bulked lengths can be had, eg. the bulked lengths can be made short and abrupt and the unbulked lengths will be substantially free of loops.

Turning now to FIG. 2 of the drawings, it will be seen that the intermittent saponifying device S according to the present invention comprises a trough or similar receptacle 54 in which is contained a quantity of any suitable saponifying agent 55. As hereinlbefore stated, the saponifying agent may be inorganic, e.g. caustic soda, caustic potash or sodium silicate, or organic, e.g. a methylamine or other lower aliphatic amine. Mounted on a pair of ledges 56 at opposite sides of the trough 54 are two pigtail guides 57 and 58 through which the yarn 13 is drawn by the [feed rolls and 11 of the downtwister D. Extending along and above the trough 54 is a rotatable shaft'59 to which is fixed, as by a set screw or a key and groove arrangement (not shown), a ring or annular transfer roller 60. The arrangement is such that the lowermost portion of the roller 60 is immersed in the saponifying agent 55, as shown at 55, and that the uppermost peripheral portion of the roller 60 is located in the path of undeflected movement of the yarn 13 across the trough 54 and between the pigtail guides 57 and 58.

Journaled adjacent the trough 54 for angular reciprocal movement about an axis substantially parallel to the axis of the shaft 59 is a shaft 61 to which is fixed a transversely extending arm 62. The arm 62 extends from the shaft 61 to a point located adjacent one side of the transfer roller 60 and is provided with yarn lifter element 63 extending across the path of travel of the yarn 13 between the pigtail guides 57 and 58. Fixedly mounted on the shaft 61 is a bushing 64 to which is connected one end of a rocker arm 65. The rocker arm 65 is bifurcated at its other end 65 and is articulated at that end to the free end 66 of a piston rod 67 extending slidably from a cylinder 68 of a pneumatic motor 69. The admission of fluid into the cylinder 68 for the purpose of reciprocating the piston (not shown) therein and therewith the piston rod 67 is controlled by a solenoid valve 70 provided with electrical conductors 72 and 73 which are adapted to be connected to the output of either the electronic relay 40 shown in FIG. 3 or the control circuit 43 shown in FIG. 4. In all respects except for the articulation joint 66, therefore, the pneumatic motor 69 is identical with the pneumatic motor 29 shown in FIG. 1.

The operation of the saponifying device according to the present invention may be briefly summarized as follows: When one of the perforations 35 of the pattern tape 34 is located between the cooperating elements of either the pick-up device 3839 or the pick-up device 41-42, a signal will be generated and transmitted via either the circuit 40 or the circuit 43 and the conductors 72 and 73 to the solenoid valve 70 for actuating the same so as to cause the piston rod 67 to be protracted from the cylinder 68. The upper end 65 of the rocker arm 65 will thus be moved to the left as shown in FIG. 2, causing the shaft 61 to be rocked in a counterclockwise direction. In this manner, the yarn lifter element 63 is moved from its raised, solid-line position to its lowered, broken-line position. This permits the yarn 13, which previously was constrained to move across the trough 54 along an angular, upwardly deflected path determined by the raised position of the lifter element 63, to travel along a substantially linear undeflected path, as shown at 13. When moving along this path, the yarn contacts the transfer roller 60 at its uppermost periphery and the latter thus transfers a quantity of the saponifying agent 55 to the yarn 13. As soon as an imperforate portion of the pattern tape interrupts the signal generated by the pick-up device, the piston rod 67 is retracted into the cylinder 68 and the shaft 61 rocked in a clockwise direction to return the lifter element 63 to its raised position. The yarn 13 is now again out of contact with the transfer roller 60 and will, therefore, not be saponified.

As in the case of the solenoid valve 30 associated with the pneumatic motor 29, of course, the solenoid valve 70 may be eliminated and replaced by a quick-acting mechanical valve 48 if a mechanical programm-ing'means such as the pattern cam 44 is employed. Furthermore, both the motor 69 and the solenoid valve 70 could be eliminated and replaced by an electromagnetic actuating device for effecting the rocking movements of the arm 65 and shaft 61, in a manner similar to that explained hereinbefore in connection with the yarn clamping discs 23 and 24.

The present invention further contemplates the provision of an apparatus for subjecting the yarn 13 to a combination treatment, i.e., an intermittent bulking operation and an intermittent saponification. To this end, the saponifying device shown in FIG. 2 can be readily incorporated in the downtwister shown in FIG. 1, it being evident from FIG. 2 that the saponifying device S would suitably be located between the pigtail guides 15 and 16 shown in FIG. 1. In this manner, there is produced a voluminous yarn which is intermittently bulked and which has an aflinity at alternating sections for normal acetate dyes and for direct or cotton dyes. Accordingly, either the yarn in its undyed state or a fabric formed from the undyed yarn can then be passed through separate baths of the two types of dyes mentioned above. The ultimate yarn or fabric will thus have a dual color effect, with the distribution of the like colored sections depending on the nature of the programming means. Merely by way of example, with a pattern tape 34 as illustrated, the color distribution will be completely random and irregular. As before, however, a certain irregularity could be attained by a tape having constant-length slots irregularly spaced or random length slots regularly spaced.

From the foregoing it will be clear that it is possible t attain in accordance with the present invention a considerable variety of relationships between the bulked and saponified sections of the yarn. Thus, arrangements can be devised in which only the saponified sections are bulked, or in which only the unsaponified sections are bulked, or in which a region of bulking in the yarn extends into both a saponified section and an unsaponified section, or in which these relationships may shift and actually go from any one of the above categories into the others without any set rule. Three representative arrangements for accomplishing such results are shown in FIGS. 6, 7 and 8 of the drawings.

Referring first to FIG. 6, it will be seen that there is here illustrated in the form of a block diagram a combined intermittent saponification and bulking system and process in which the yarn taken from a supply package or spool 14 is passed through a saponifying device S as shown in FIG, 2 and is then fed by feed rolls -11 to an intermittent bulking device B consisting of a jet intermittently supplied with air and yarn clamping device 21 as shown in FIG. 1. Thereafter, the yarn is wound onto a suitable take-up spool 19. A pattern tape 34 constitutes the programming means. The perforated and imperforate portions of the pattern tape 34 are sensed by the spaced sensing elements of a pick-up unit P (either the electrodes 38 and 39 or the light source 41 and. photosensitive cell 42). The pick-up unit generates a signal in response to the passing of a tape perforation between the sensing elements of the pick-up unit, which signal is sent simultaneously to the intermittent saponifying device S and to the intermittent bulking device B. In the illustrated arrangement, therefore, the signal would be delivered to the solenoid valves 3t? and 70 and to the solenoid valve (not shown) which controls the line 22 leading into the jet 2% With this arrangement, the treatment of the yarn is such that the saponified sections of the yarn do not necessarily coincide with the bulked sections of the yarn, although such coincidence may occur. This is due to the fact that, although both the bulking and saponifying operations take place at exactly the same instant, each bulked section always leads the saponified section which is formed at the same time. Thus, any given saponified section would not necessarily be bulked unless the distance between the saponifying device S and the bulking device B were an exact multiple of the length of the same saponified section. This, however, is an eventuality which could only occur very rarely in view of the random dimensioning and spacing of the perforations in the pattern tape 34. The resultant yarn not only has irregularly dimensioned and spaced bulked sections as well as irregularly dimensioned and spaced saponified sections, but is also characterized by a completely random arrangement and distribution of the bulked sections relative to the saponified and unsaponified sections. A change in the dimensions and/ or spacing of the slots or perforations 35 will, of course, change these relationships correspondingly.

The same result can be attained by employing two pattern tapes and two pick-up units without any particular or predetermined timing relationship between the pattern tapes and without any predetermined relationship between the dimensions and spacing of the perforations in the respective tapes.

Referring now to FIG. 7, the yarn treating system there illustrated in the form of a block diagram is substantially identical with that shown in FIG. 6 but differs therefrom in that two pick-up units P and P" are employed to sense the perforations in the pattern tape 34. The first pickup unit P delivers its signal only to the saponifying device S, while the second pick-up unit P delivers its signal only to the bulking device B. With respect to this latter sig nal, it is to be understood that the same may be delivered,

as illustrated, to the two solenoid valves which control the flow of fluid to the jet 20 and to the yarn clamping device 21, but if desired the signal may be delivered only to the yarn clamping or tensioning device, especially if a continuous flow of bulking fluid to the jet is maintained. An arrangement of the type just described, i.e., where two pick-up units are arranged in tandem for sensing the same pattern tape, renders possible a yarn treatment in which each saponified section is bulked while each 11nsaponified section is unbulked, or in which each unsaponified section is bulked while each saponified section is unbulked. To accomplish this result, it is necessary to establish a predetermined relationship between the spacing of the pick-up units from one another and the spacing of the saponifying device S from the bulking device B. This relationship can be expressed by the formula wherein l =distance between pick-up units,

l =yarn distance from saponification point to bulking point,

V =pattern tape speed, and

V =yarn speed.

Substantially the same effect can be attained through the use of two pick-up units P and P each of which is arranged to sense a respective one of a pair of pattern tapes 34' and 34 (see FIG. 8) provided with substantially equivalent patterns of perforations. As an alternative to the foregoing, the two pick-up units. could be employed in conjunction with a single pattern tape in which are provided two channels of perforations, with each pickup unit sensing the perforations in one of the channels. The treatment carried out by a system of this type will be the same as that carried out by the system of FIG. 7 as long as the distance between the pick-up units satisfies the relationship defined by the formula set forth hereinabove.

It will be understood that the ultimate characteristics of the yarn wound onto the take-up spool 19 depends on a number of factors over and above those included in the above formula. Thus, the initial denier of the parent or source yarn, the number of filaments making up the yarn, the type of jet employed and the operating conditions thereof, the initial and final twists imparted to the yarn, and the distance between the jet and the yarn tensioning or clamping device, as well as the types of properties of the saponifying agent and dyes employed, all contribute to the ultimate appearance of the product yarn. For example, the pressure of the bulking fluid admitted into the jet 20 may vary from about 20 p.s.i.g. or less to about p.s.i.g. or more, but for optimum bulk fullness the pressure should be about 40 to 60 p.s.i.g. The distance between the jet 20 and the clamping device 21 may be as little as inch and as great as 6 inches or more, depending on the lengths of bulked sections desired. Bulked length, of course, varies not only as a direct function of this distance, but also as a direct function of the feed roll speed, i.e., the quantity V for any given time signal generated by the pick-up unit controlling the bulking device. The state of twist of the yarn has been found to have no appreciable effect on the bulked length as such, but it does effect the appearance of the product yarn in that with an increase in twist the ends of the bulked sections become more abrupt.

In place of, as well as possibly in addition to, the saponification the running yarn may intermittently be contacted with one or more dye liquors to impart varied color effects directly. If volatile solvents are employed they will for the most part be evaporated during ballooning immediately preceding take-up on the bobbin by the downtwister. If effected prior to air jet bulking obviously the pressurized air will aid in drying the yarn. In

1 1 the event, however, that a more positive cleaning is desired the fully wound bobbin may be immersed in wash liquors, followed by drying.

The features of the present invention will be more clearly appreciated from a consideration of the following examples.

Example I A 300 denier source yarn made up of 85 cellulose acetate filaments with 0.27 turn per inch, is unwound from the supply package 14 and fed by the feed rolls and 11 through an air jet and past the clamping device 21 to the take-up spool 19. The feed roll peripheral speed is 73 yards per minute, and the air pressure in the bulking jet is p.s.i.g. The distance between the jet and the clamping device is A; inch. A signal from the pattern pick-up. unit is employed to actuate both the clamping or tensioning device and the air feed to the jet at the same instant. The proportion of time during which discs 23 and 24 are in contact to permit bulking is set to provide a production rate of about 22 yards per minute. Under these conditions the bulked portions vary in length between about 1.5 and 9 inches.

Example II The operation of Example I is repeated, with a yarn twist of 5 turns per inch and a feed roll speed of 33 yards per minute. Air pressure in the jet is set at p.s.i.g. The distance between the jet and the tensioning device is 6 inches. Under these conditions bulked or slub length is between about 5 and 12 inches.

Example III A yarn similar to that employed as the parent yarn in Example II is first passed over a saponifying device such as that shown in FIG. 2. The saponifying agent in the trough is a 15% solution of sodium hydroxide in water. The yarn lifter is intermittently actuated by the same signal as the tensioning device so as to form alternating saponified and unsaponified sections in the yarn. Thereafter the yarn is subjected to the treatment conditions set forth in Example II. The resultant product yarn when woven into fabric and dyed with an acetate dye and with a direct or cotton dye imparts to the fabric a novel and highly pleasing dual color effect.

Example IV The process of Example III is repeated with the following changes: In place of sodium hydroxide the trough 12 contains a solution made up, by weight, of parts of ethyl alcohol, 25 parts of water and 1.5 parts of Xylene Milling Blue GL. The bulking treatment is omitted. The resulting yarn is dry on the bobbin and is intermittently colored blue.

Yarns made in accordance with the teachings of the present invention can be employed in the manufacture of a variety of consumer products in which specialty effects are desired. For example, such yarns can be employed in the manufacture of fabrics for mens suits and coats, upholstery and furniture coverings, automobile seat covers, carpeting, blankets, drapes and the like. I

It is to be understood that the foregoing detailed description is given merely by way of illustration and that many variations may be made therein without departing from the spirit of our invention.

Having described our invention what we desire to secure by Letters Patent is:

1. A yarn containing along its length intermittent dyed sections and intermittent voluminous sections, said dyed sections overlapping said voluminous sections.

2. A yarn having a basis of an organic ester of cellulose containing along its length intermittent sections in which ester groups of said cellulose ester have been replaced by hydroxyl groups, and intermittent bulky sections, said sections in which ester groups have been replaced by hydroxyl groups overlapping said bulky sections.

3. A yarn comprising cellulose acetate and containing randomly along its length intermittent bulky and intermittent dyed sections, said bulky sections overlapping said dyed sections.

References Cited by the Examiner UNITED STATES PATENTS 1,909,192 5/1933 Taylor 57-140 1,966,440 7/1934 Dickie et al. 57l40 1,992,259 2/1935 Taylor 188 2,504,183 4/1950 Craft 28-75 2,647,285 8/1953 Pfarr 2872 2,807,864 10/1957 Head 2875 X 2,978,788 4/1961 Keefe 28-75 3,017,737 1/1962 Breen 5734 3,105,349 10/1963 Palm et al. 5734 FRANK J. COHEN, Primary Examiner. MERVIN STEIN, Examiner.

J. PETRAKES, Assistant Examiner. 

2. A YARN HAVING A BASIS OF AN ORGANIC ESTER OF CELLULOSE CONTAINING ALONG ITS LENGTH INTERMITTENT SECTIONS IN WHICH ESTER GROUPS OF SAID CELLULOSE ESTER HAVE BEEN REPLACED BY HYDROXYL GROUPS, AND INTERMITTENT BULKY SECTIONS, SAID SECTIONS IN WHICH ESTER GROUPS HAVE BEEN REPLACED BY HYDROXYL GROUPS OVERLAPPING SAID BULKY SECTIONS. 